Magnetic impulse applied sleeve method of forming a wellbore casing

ABSTRACT

A method of forming a wellbore casing within a borehole that traverses a subterranean formation includes the steps of assembling a tubular liner by coupling a threaded portion of a first tubular member to a threaded portion of a second tubular member and coupling a tubular sleeve to the threaded portions of the first and second tubular members. The method further includes positioning the wellbore casing within the borehole and radially expanding and plastically deforming the wellbore casing assembly within the borehole. The step of coupling the tubular sleeve through the threaded portions of the and second tubular members includes applying impulsive magnetic energy to the tubular sleeve.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage patent application for PCTpatent application Ser. No. PCT/US2003/025677, filed on Aug. 18, 2003,which claimed the benefit of the filing dates of (1) U.S. provisionalpatent application Ser. No. 60/405,610, filed on Aug. 23, 2002, thedisclosures of which are incorporated herein by reference.

The present application is related to the following: (1) U.S. patentapplication Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patentapplication Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. Pat.No. 6,328,113, (5) U.S. patent application Ser. No. 09/523,460, filed onMar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed onFeb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed onFeb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed onJun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed onApr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635,filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No.60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S.provisional patent application Ser. No. 60/159,082, filed on Oct. 12,1999, (14) U.S. provisional patent application Ser. No. 60/159,039,filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser.No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patentapplication Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S.provisional patent application Ser. No. 60/165,228, filed on Nov. 12,1999, (18) U.S. provisional patent application Ser. No. 60/221,443,filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser.No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patentapplication Ser. No. 60/233,638, filed on Sep. 18, 2000, (21) U.S.provisional patent application Ser. No. 60/237,334, filed on Oct. 2,2000, (22) U.S. provisional patent application Ser. No. 60/270,007,filed on Feb. 20, 2001, (23) U.S. provisional patent application Ser.No. 60/262,434, filed on Jan. 17, 2001, (24) U.S. provisional patentapplication Ser. No. 60/259,486, filed on Jan. 3, 2001, (25) U.S.provisional patent application Ser. No. 60/303,740, filed on Jul. 6,2001, (26) U.S. provisional patent application Ser. No. 60/313,453,filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser.No. 60/317,985, filed on Sep. 6, 2001, (28) U.S. provisional patentapplication Ser. No. 60/3318,386, filed on Sep. 10, 2001, (29) U.S.patent application Ser. No. 09/969,922, filed on Oct. 3, 2001, (30) U.S.patent application Ser. No. 10/016,467, filed on Dec. 10, 2001; (31)U.S. provisional patent application Ser. No. 60/343,674, filed on Dec.27, 2001; (32) U.S. provisional patent application Ser. No. 60/346,309,filed on Jan. 7, 2002; (33) U.S. provisional patent application Ser. No.60/372,048, filed on Apr. 12, 2002; (34) U.S. provisional patentapplication Ser. No. 60/380,147, filed on May 6, 2002; (35) U.S.provisional patent application Ser. No. 60/387,486, filed on Jun. 10,2002; (36) U.S. provisional patent application Ser. No. 60/387,961,filed on Jun. 12, 2002; (37) U.S. provisional patent application Ser.No. 60/391,703, filed on Jun. 26, 2002; (38) U.S. provisional patentapplication Ser. No. 60/397,284, filed on Jul. 19, 2002, and (39) U.S.provisional patent application Ser. No. 60/405,394, filed on Aug. 23,2003, the disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration.

Conventionally, when a wellbore is created, a number of casings areinstalled in the borehole to prevent collapse of the borehole wall andto prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

During oil exploration, a wellbore typically traverses a number of zoneswithin a subterranean formation. Wellbore casings are then formed in thewellbore by radially expanding and plastically deforming tubular membersthat are coupled to one another by threaded connections. Existingmethods for radially expanding and plastically deforming tubular memberscoupled to one another by threaded connections are not always reliable,and do not always produce satisfactory results. In particular, thethreaded connections can be damaged during the radial expansion process.Furthermore, the threaded connections between adjacent tubular members,whether radially expanded or not, are typically not sufficiently coupledto permit the transmission of energy through the tubular members fromthe surface to the downhole location.

The present invention is directed to overcoming one or more of thelimitations of the existing procedures for forming new sections ofcasing in a wellbore.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method of forming awellbore casing within a borehole that traverses a subterraneanformation is provided that includes externally applied tubular sleevefor improved sealing a wellbore casing joints.

According to another aspect of the present invention, a method offorming a wellbore casing within a borehole that traverses asubterranean formation is provided that includes magnetic impulse methodfor externally applying a tubular sleeve for improved sealing ofwellbore casing joints.

According to another aspect of the present invention, a method offorming a wellbore casing within a borehole that traverses asubterranean formation is provided that includes expanding joinedtubular members such as joined wellbore casings with a tubular sleeveexternally applied to the surfaces of the joined wellbore casing andoverlapping the joint thereby maintaining an improved seal of thewellbore casing joints after expansion.

According to another aspect of the present invention, a method ofimproving the seal of tubular members that are connected and thenexpanded is provided, that includes using a magnetic impulse method forexternally applying a tubular sleeve to the joint between the tubularmembers prior to expanding the connected tubular members.

According to another aspect of the present invention, an improved methodof connecting wellbore casing tubular member is provided that includesforming raised ring portions to enhance surface contact stress in thecoupling connection and subsequently applying inward radial force with atubular sleeve imposed by magnetic impulse method for improved sealingof the joints between the tubular members.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-sectional schematic illustration of afirst tubular member, such a first wellbore casing, for placement withina borehole that traverses a subterranean formation.

FIG. 2 is a fragmentary cross-sectional schematic illustration of thefirst tubular member, such as the first wellbore casing as in FIG. 1 andan aligned second tubular member, such as a second wellbore casing inposition for coupling together and for placing the first and secondtubular members, such as the depicted wellbore casings within aborehole.

FIG. 3 is a fragmentary cross-sectional schematic illustration of firstand second wellbore casings of FIG. 2 after overlapping coupling as withthe first female threads and second male threads providing asubstantially continuous wellbore that may be radially expanded andplastically deformed at the overlapping portions of the first and secondwellbore casings.

FIG. 4 is a fragmentary cross-sectional schematic illustration of thecoupling joint of FIG. 3 after placing a tubular sleeve axially alignedwith the first and second wellbore casings, and overlappingly positionedat the joint formed by coupling the first and second wellbore casings.

FIG. 5 is a fragmentary cross-sectional schematic illustration of thefirst and second wellbore casings and of the tubular sleeve of FIG. 4and further schematically depicting one illustration of a magneticimpulse apparatus positioned at the tubular sleeve for externallyapplying the tubular sleeve for improved sealing of the joint formed bycoupling the wellbore casings together.

FIG. 6 is a fragmentary cross-sectional schematic illustration of theapparatus of FIG. 5, after applying magnetic impulse force to thetubular sleeve for improved sealing of the joint formed by coupling thefirst and second wellbore casings of FIG. 5.

FIG. 7 is a fragmentary cross-sectional schematic illustration of ajoint of a first and second tubular member, such as a first and secondwellbore casing, having a tubular sleeve externally applied to theadjacent external surfaces of the first and second tubular members atthe overlapping joint there between prior to expanding the first andsecond tubular members at the area of the joint, according to one aspectof the present invention.

FIG. 8 is a fragmentary cross-sectional schematic illustration of theapparatus of FIG. 7, after the coupled portion of the first and secondtubular member wellbore casings and the externally applied tubularsleeve have been radially expanded and plastically deformed according toone aspect of the present invention.

FIG. 9 is a fragmentary cross-sectional schematic illustration of thefirst female coupling and second male coupling and overlapping tubularsleeve with raised ridges interposed between the couplings to increasethe surface to surface contact stress for maintaining sealing contactupon expanding and plastically deforming the coupling and tubular sleeveat the overlapping portions of the first and second tubular members.

FIG. 10 is a fragmentary cross-sectional schematic illustration of analternative embodiment of the invention in which an interior tubularsleeve 41 is aligned with the coupling joint between tubular members andthe interior tubular sleeve 41 is forced outward and applied to theinterior surfaces of the tubular members by a magnetic impulse device.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1, a borehole 10 that traverses a subterraneanformation 12 includes a first tubular member 14, such as a firstwellbore casing 14 that is positioned within and coupled to theborehole. In several exemplary embodiments, tubular members in the formof wellbore casings will be described and depicted. It will beunderstood that although the methods, particularly advantageous forforming wellbore casings, certain advantageous features may also beapplicable to other tubular members as described and claimed herein. Inan illustrative embodiment, the first wellbore casing 14 may, forexample, be positioned within and coupled to the borehole 10 using anynumber of conventional methods and apparatus, that may or may notinclude radial expansion and plastic deformation of the first wellborecasing 14, and/or using one or more of the methods and apparatusdisclosed in one or more of the following: (1) U.S. patent applicationSer. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent applicationSer. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent applicationSer. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. Pat. No.6,328,113, (5) U.S. patent application Ser. No. 09/523,460, filed onMar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed onFeb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed onFeb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed onJun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed onApr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635,filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No.60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S.provisional patent application Ser. No. 60/159,082, filed on Oct. 12,1999, (14) U.S. provisional patent application Ser. No. 60/159,039,filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser.No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patentapplication Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S.provisional patent application Ser. No. 60/165,228, filed on Nov. 12,1999, (18) U.S. provisional patent application Ser. No. 60/221,443,filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser.No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patentapplication Ser. No. 60/233,638, filed on Sep. 18, 2000, (21) U.S.provisional patent application Ser. No. 60/237,334, filed on Oct. 2,2000, (22) U.S. provisional patent application Ser. No. 60/270,007,filed on Feb. 20, 2001, (23) U.S. provisional patent application Ser.No. 60/262,434, filed on Jan. 17, 2001, (24) U.S, provisional patentapplication Ser. No. 60/259,486, filed on Jan. 3, 2001, (25) U.S.provisional patent application Ser. No. 60/303,740, filed on Jul. 6,2001, (26) U.S. provisional patent application Ser. No. 60/313,453,filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser.No. 60/317,985, filed on Sep. 6, 2001, (28) U.S. provisional patentapplication Ser. No. 60/3318,386, filed on Sep. 10, 2001, (29) U.S.utility patent application Ser. No. 09/969,922, filed on Oct. 3, 2001,(30) U.S. utility patent application Ser. No. 10/016,467, filed on Dec.10, 2001; (31) U.S. provisional patent application Ser. No. 60/343,674,filed on Dec. 27, 2001; (32) U.S. provisional patent application Ser.No. 60/346,309, filed on Jan. 7, 2002; (33) U.S. provisional patentapplication Ser. No. 60/372,048, filed on Apr. 12, 2002; (34) U.S.provisional patent application Ser. No. 60/380,147, filed on May 6,2002; (35) U.S. provisional patent application Ser. No. 60/387,486,filed on Jun. 10, 2002; (36) U.S. provisional patent application Ser.No. 60/387,961, filed on Jun. 12, 2002; (37) U.S. provisional patentapplication Ser. No. 60/391,703, filed on Jun. 26, 2002; (38) U.S.provisional patent application Ser. No. 60/397,284, filed on Jul. 19,2002, and (39) U.S. provisional patent application Ser. No. 60/405,394,filed on Aug. 23, 2003, the disclosures of which are incorporated hereinby reference.

Referring to FIG. 2, the second tubular member 16, such as secondwellbore casing 16 is then overlappingly coupled to the first wellborecasing 14 for positioning within the borehole 10. In several exemplaryembodiments, the first wellbore casing 14 may, for example, be coupledat a first coupling portion 18 to a second coupling portion 20 of thesecond wellbore casing 16 using any number of conventional methods andapparatus. For example as shown in FIG. 2, the coupling may comprise amale, or externally, threaded portion 24 engaged with a female, orinternally, threaded portion 26. The method of coupling may or may notinclude radial expansion and plastic deformation of either of thewellbore casings 14 or 16 or both, and or using one of more of themethods disclosed in one of more of the following: (1) U.S. patentapplication Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patentapplication Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. Pat.No. 6,328,113, (5) U.S. patent application Ser. No. 09/523,460, filed onMar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed onFeb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed onFeb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed onJun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed onApr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635,filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No.60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S.provisional patent application Ser. No. 60/159,082, filed on Oct. 12,1999, (14) U.S. provisional patent application Ser. No. 60/159,039,filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser.No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patentapplication Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S.provisional patent application Ser. No. 60/165,228, filed on Nov. 12,1999, (18) U.S. provisional patent application Ser. No. 60/221,443,filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser.No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patentapplication Ser. No. 60/233,638, filed on Sep. 18, 2000, (21) U.S.provisional patent application Ser. No. 60/237,334, filed on Oct. 2,2000, (22) U.S. provisional patent application Ser. No. 60/270,007,filed on Feb. 20, 2001, (23) U.S. provisional patent application Ser.No. 60/262,434, filed on Jan. 17, 2001, (24) U.S, provisional patentapplication Ser. No. 60/259,486, filed on Jan. 3, 2001, (25) U.S.provisional patent application Ser. No. 60/303,740, filed on Jul. 6,2001, (26) U.S. provisional patent application Ser. No. 60/313,453,filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser.No. 60/317,985, filed on Sep. 6, 2001, (28) U.S. provisional patentapplication Ser. No. 60/3318,386, filed on Sep. 10, 2001, (29) U.S.utility patent application Ser. No. 09/969,922, filed on Oct. 3, 2001,(30) U.S. utility patent application Ser. No. 10/016,467, filed on Dec.10, 2001; (31) U.S. provisional patent application Ser. No. 60/343,674,filed on Dec. 27, 2001; (32) U.S. provisional patent application Ser.No. 60/346,309, filed on Jan. 7, 2002; (33) U.S. provisional patentapplication Ser. No. 60/372,048, filed on Apr. 12, 2002; (34) U.S.provisional patent application Ser. No. 60/380,147, filed on May 6,2002; (35) U.S. provisional patent application Ser. No. 60/387,486,filed on Jun. 10, 2002; (36) U.S. provisional patent application Ser.No. 60/387,961, filed on Jun. 12, 2002; (37) U.S. provisional patentapplication Ser. No. 60/391,703, filed on Jun. 26, 2002; (38) U.S.provisional patent application Ser. No. 60/397,284, filed on Jul. 19,2002, and (39) U.S. provisional patent application Ser. No. 60/405,394,filed on Aug. 23, 2003, the disclosures of which are incorporated hereinby reference.

Upon coupling the first and second tubular members, such as uponcoupling the first and second wellbore casings 14 and 16, as depicted inFIG. 2, a first surface portion 26 and a second surface portion 28 areadjacently positionally in the axial direction and may or may not havethe same or nearly the same outside diameters 32 and 34. It wouldunderstood that according to the foregoing methods and apparatus forexpanding the wellbore casing, the depiction in FIG. 2 and FIG. 3 may ormay not demonstrate an overlapping portion that has been previouslyexpanded. In either instance, it is desirable for the present inventionthat the exterior first outside diameter 32 and the outside diameter 34have the same or nearly the same dimensions. For further be seen that ajoint 30 is formed there between that may include a small gap such as abevel or partial channel on either member as is conventional foraccommodating nicks or dents so that they will not interfere withcomplete coupling between the first and second wellbore casings.

Referring to FIG. 3, it will again be understood that the first wellborecasing 14 and the second wellbore casing 16 may or may not have beenradially expanded in the depiction of FIG. 4. A tubular sleeve 40 ispositioned overlapping the first surface portion 26 of the firstwellbore casings 14 and also overlapping the second surface portion 28of the second wellbore casing 16, thereby overlapping the joint 30 andaxially extending in either direction there from at least partially overthe overlapping coupling as well as partially over a portion of casing16 that does not overlap first wellbore casing 14.

The tubular sleeve 40 is preferably composed of electrically conductivematerial that are suitably malleable or flowable to be shapedmechanically, as for example copper, aluminum, light metal, and metalalloys. Steel alloys and other metal alloys with suitable electricallyconductivity and with suitable malleability or suitable flow behaviormay also be used. The inside diameter 42, of the tubular sleeve 40 isonly slightly larger than the outside diameter of at the joint 30 thefirst tubular member 14 or the second tubular member 16. This means acylindrical gap 44 between the inside surface 46 of sleeve 40 and thefirst and outside surfaces 26 and 28 of wellbore casings 14 and 16respectively. The outside diameter 48 of tubular sleeve 40 is slightlylarger than the inside diameter 42 defining a thickness 49 that isrelatively thin compared the thickness of the wellbore casings 14 and16.

FIG. 5 is a schematic illustration of the overlapping wellbore casings14 and 16 and the overlapping tubular sleeve 40, as in FIG. 4, andfurther schematically depicts a magnetic impulse energy applicator 50.The impulse energy applicator 50, according to one aspect of the presentinvention, is aligned with the tubular sleeve at a position overlappingthe joint 30 and extending a distance over the surfaces 26 and 28 oneither side of the joint 30. The magnetic impulse apparatus 50 maycomprise an impulse conductor ring 52 having an inside diameter 54slightly larger than the outside diameter of the ring 40, therebyleaving a small cylindrical gap 56 there between. Conductor ring 52 isinterrupted with a radially extending gap (not shown) and is operativelyconnected to an impulse generator 58 such that the magnetic impulsepower flows circumferentially around conductor ring 52 when applied fromthe impulse generator 58. This method applied to joints of wellborecasing has not heretofore been known, although there are conventionaldevices and it is a conventional concept for providing a magneticimpulse for shaping of cylindrical metal parts. Thus, the adaptation ofone of more of the methods and apparatus according to one or more of thefollowing may be used in connection with this aspect of the presentinvention: (1) U.S. Pat. No. 5,444,963 issued to Steingroever, et al.,Aug. 29, 1995; (2) U.S. Pat. No. 5,586,460 issued to Steingroever Dec.24, 1996; (3). U.S. Pat. No. 5,953,805 issued to Steingroever Sep. 21,1999, as well as the techniques an apparatus is described on the webpage of Magnetic-Physics, Inc., with reference to the shaping techniqueunder the trademark Magnetopuls, the disclosures of which areincorporated by reference.

With reference to FIG. 6, the method of applying the tubular sleeve tothe joint of wellbore casing 14 and 16 may be more fully understood. Themagnetic impulse generator 58 provides a magnetic in pulse to theconductor ring 52. The magnetic impulse causes a powerful magnetic field60 to be produced and simultaneously causes a counter current magneticpulse 62 to be produced within tubular sleeve 40. An extremely highconcentration of magnetic flux at 64 results in the gap 56 betweentubular sleeve 40 and impulse ring 52. This high flux concentration dueto the magnetic impulse generates a large force 66 inward from the ring52 thereby collapsing tubular sleeve 40 onto the surfaces 26 and 28 atthe joint. This effectively forms a first sealing interface 70 betweenthe first surface 26 and the inside surface 44 of the tubular sleeve,and also forms a sealing interface 72 between the inside surface 44 ofthe tubular sleeve and the surface 28 of the second wellbore casing.With sufficiently high force, the malleable or flowable material fromwhich tubular sleeve 40 is made, flows at 74 into the joint gap 30. Thismethod produces a surface to surface air tight metallic seal entirelyover the coupling between the first wellbore casing 14 and the secondwellbore casing 16. The strength of the tubular sleeve 40 also holds thejoint together during the process of mechanical expansion of thewellbore casing at the joint.

In an exemplary embodiment, as illustrated in FIGS. 7 and 8, the firstand second tubular members, 14 and 16, and the tubular sleeve 40 maythen be positioned within another structure 10 such as, for example, awellbore 10, and radially expanded and plastically deformed, forexample, by moving an expansion cone 80 through the interiors of thefirst and second tubular members 14 and 16. The tapered portions, 76 and78, of the tubular sleeve 40 as may result from material flow due tolarge magnetic force of the type of material of sleeve 40 and facilitatethe insertion and movement of the first and second tubular members 14and 16 within and through the structure 10, and the movement of theexpansion cone 80 through the interiors of the first and second tubularmembers, 14 and 16, may be from top to bottom or from bottom to top.

In an exemplary embodiment, during the radial expansion and plasticdeformation of the first and second tubular members, 14 and 16, thetubular sleeve 40 is also radially expanded and plastically deformed. Inan exemplary embodiment, as a result, the tubular sleeve 40 may bemaintained in circumferential tension and the overlapping end couplingportions, 18 and 20, of the first and second tubular members, 14 and 16,may be maintained in circumferential compression.

In FIG. 9, a fragmentary cross-sectional schematic illustration shows anexemplary embodiment of method and apparatus in which first and secondtubular members 114 and 116 are overlapping coupled together, as with afirst coupling portion 118 and a second coupling portion 120 pressedtogether in surface-to-surface engagement, and with an overlappingtubular sleeve 40 applied to the exterior thereof and providing asubstantially continuous tubular assembly that may be expanded andplastically deformed. The first coupling portion 118 and the secondcoupling portion 120 may be overlappingly coupled together, as with afirst female coupling portion and a second male coupling portion pushed,slid or pressed together in surface-to-surface engagement, and Anoverlapping tubular sleeve 40 is applied to the coupling to providesealing and to stress the tubular coupling portions toward each other.In an exemplary embodiment, one or more raised ridge rings 84(a-c) andcorresponding troughs rings 86(a-c) are formed interposed between thefirst and second couplings to increase the surface to surface contactstress for maintaining sealing contact upon expanding and plasticallydeforming the coupling and tubular sleeve at the overlapping portions ofthe first and second tubular members. In this method and apparatus thepeaks 88(a-c) of the ridges 84(a-c) have a small area of surface contactwith the opposed coupling portion, compared to the entire overlappingcoupling area, such that the stress or force per area of contact issignificantly increased thereby facilitating the surface to surface sealat the coupling joint. Although the ridge rings 84 are shown formed inthe second male coupling portion with the peaks toward the first femalemale coupling portion, it will be understood based upon this disclosurethat the ridge rings 84 might alternatively be formed on the femalecoupling portion 118 with the peaks toward the female coupling portion120. The tubular sleeve 40 as applied to the exterior of the overlappingtubular members increases the sealing stress. In a further exemplaryembodiment, the tubular sleeve 40 acting together with the raised ridgerings 84 work together to maintain the seal when the tubular members 114and 116 are expanded and plastically deformed as disclosed herein.

FIG. 10 depicts another exemplary embodiment of the invention in whichan interior tubular sleeve 41 is aligned with coupling joint betweentubular members 14 and 16. Before or after expanding the tubular membersthe interior tubular sleeve 41 is forced outward by magnetic impulsedevice 51 in a conventional manner or the adaptation of one of more ofthe methods and apparatus according to one or more of the following maybe used in connection with this aspect of the present invention: (1)U.S. Pat. No. 5,444,963 issued to Steingroever, et al., Aug. 29, 1995;(2) U.S. Pat. No. 5,586,460 issued to Steingroever Dec. 24, 1996; (3).U.S. Pat. No. 5,953,805 issued to Steingroever Sep. 21, 1999, as well asthe techniques an apparatus is described on the web page ofMagnetic-Physics, Inc., with reference to the shaping technique underthe trademark Magnetopuls, the disclosures of which are incorporated byreference. The interior sleeve 41 is applied to the interior surfaces ofthe tubular members overlapping the coupling joint and therebyfacilitates sealing and connection between the tubular members.

As more fully disclosed in U.S. provisional patent application No.60/405,394, filed on Aug. 23, 2002, the disclosure of which isincorporated herein by reference, one or more layers or coatings ofsofter material, preferably metallic material having a modulus ofelasticity lower than the modulus of elasticity of the tubular membersat the coupling joint, may be interposed between the joints, tofacilitate sealing before and after expanding and plastically deformingjoined tubular members such as wellbore casings. The interposed materialmay also be a material of the type having a lower melting point beforedeformation than after deformation. For example the material may be anexothermic material that initially releases energy upon stress or heatinput thereby melting or plastically flowing at one temperature andsubsequently without the further release of such heat energy having ahigher melting point or plastic flow temperature.

In several exemplary embodiments, the first and second tubular members,14 and 16, are radially expanded and plastically deformed using theexpansion cone 80 in a conventional manner and/or using one or more ofthe methods and apparatus disclosed in one or more of the following: (1)U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2)U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3)U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4)U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5)U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6)U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7)U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8)U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9)U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000,(10) PCT patent application Ser. No. PCT/US00/18635, filed on Jul. 9,2000, (11) U.S. provisional patent application Ser. No. 60/162,671,filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No.60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patentapplication Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S.provisional patent application Ser. No. 60/159,039, filed on Oct. 12,1999, (15) U.S. provisional patent application Ser. No. 60/159,033,filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser.No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patentapplication Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S.provisional patent application Ser. No. 60/221,443, filed on Jul. 28,2000, (19) U.S. provisional patent application Ser. No. 60/221,645,filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser.No. 60/233,638, filed on Sep. 18, 2000, (21) U.S. provisional patentapplication Ser. No. 60/237,334, filed on Oct. 2, 2000, (22) U.S.provisional patent application Ser. No. 60/270,007, filed on Feb. 20,2001, (23) U.S. provisional patent application Ser. No. 60/262,434,filed on Jan. 17, 2001, (24) U.S, provisional patent application Ser.No. 60/259,486, filed on Jan. 3, 2001, (25) U.S. provisional patentapplication Ser. No. 60/303,740, filed on Jul. 6, 2001, (26) U.S.provisional patent application Ser. No. 60/313,453, filed on Aug. 20,2001, (27) U.S. provisional patent application Ser. No. 60/317,985,filed on Sep. 6, 2001, (28) U.S. provisional patent application Ser. No.60/3318,386, filed on Sep. 10, 2001, (29) U.S. utility patentapplication Ser. No. 09/969,922, filed on Oct. 3, 2001, (30) U.S.utility patent application Ser. No. 10/016,467, filed on Dec. 10, 2001;(31) U.S. provisional patent application Ser. No. 60/343,674, filed onDec. 27, 2001; (32) U.S. provisional patent application Ser. No.60/346,309, filed on Jan. 7, 2002; (33) U.S. provisional patentapplication Ser. No. 60/372,048, filed on Apr. 12, 2002; (34) U.S.provisional patent application Ser. No. 60/380,147, filed on May 6,2002; (35) U.S. provisional patent application Ser. No. 60/387,486,filed on Jun. 10, 2002; (36) U.S. provisional patent application Ser.No. 60/387,961, filed on Jun. 12, 2002; (37) U.S. provisional patentapplication Ser. No. 60/391,703, filed on Jun. 26, 2002; (38) U.S.provisional patent application Ser. No. 60/397,284, filed on Jul. 19,2002, and (39) U.S. provisional patent application Ser. No. 60/405,394,filed on Aug. 23, 2003, the disclosures of which are incorporated hereinby reference.

In several alternative embodiments, the first and second tubularmembers, 14 and 16, are radially expanded and plastically deformed usingother conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurizationand/or roller expansion devices such as, for example, that disclosed inU.S. patent application publication no. US 2001/0045284 A1, thedisclosure of which is incorporated herein by reference.

The use of the tubular sleeve 40 during (a) the coupling of the firsttubular member 19 to the second tubular member 16, (b) the placement ofthe first and second tubular members in the structure 10, (c) the radialexpansion and plastic deformation of the first and second tubularmembers, and (d) magnetic impulse applying tubular sleeve to theoverlapping coupling ends between the first and second tubular membersprovides a number of significant benefits. For example, the tubularsleeve 40 protects the exterior surfaces of the end portions, 18 and 20,of the first and second tubular members, 14 and 16, during handling andinsertion of the tubular members within the structure 10. In thismanner, damage to the exterior surfaces of the end portions, 18 and 20,of the first and second tubular member, 14 and 16, are prevented thatcould result in stress concentrations that could result in acatastrophic failure during subsequent radial expansion operations.Furthermore, the tubular sleeve 40 provides an alignment guide thatfacilitates the insertion and threaded coupling of the second tubularmember 16 to the first tubular member 14. In this manner, misalignmentthat could result in damage to the threaded connections, 22 and 24, ofthe first and second tubular members, 14 and 16, may be avoided. Inaddition, during the relative rotation of the second tubular member withrespect to the first tubular member, required during the threadedcoupling of the first and second tubular members, the tubular sleeve 40provides an indication of to what degree the first and second tubularmembers are threadably coupled. For example, if the tubular sleeve 40can be easily rotated, that would indicate that the first and secondtubular members, 14 and 16, are not fully threadably coupled and inintimate contact with the internal flange 36 of the tubular sleeve.Furthermore, the tubular sleeve 16 may prevent crack propagation duringthe radial expansion and plastic deformation of the first and secondtubular members, 14 and 16. In this manner, failure modes such as, forexample, longitudinal cracks in the end portions, 18 and 20, of thefirst and second tubular members may be limited in severity oreliminated all together. In addition, after completing the radialexpansion and plastic deformation of the first and second tubularmembers, 14 and 16, the tubular sleeve 40 may provide a fluid tightmetal-to-metal seal between interior surface of the tubular sleeve andthe exterior surfaces of the end portions, 18 and 20, of the first andsecond tubular members. In this manner, fluidic materials are preventedfrom passing through the threaded connections, 22 and 24, of the firstand second tubular members, 14 and 16, into the annulus between thefirst and second tubular members and the structure 10. Furthermore,because, following the radial expansion and plastic deformation of thefirst and second tubular members, 14 and 16, the tubular sleeve 40 maybe maintained in circumferential tension and the end portions, 18 and20, of the first and second tubular members, 14 and 16, may bemaintained in circumferential compression, axial loads and/or torqueloads may be transmitted through the tubular sleeve. In addition, thetubular sleeve 40 may also increase the collapse strength of the endportions, 18 and 20, of the first and second tubular members, 14 and 16.

A useful method of forming a wellbore casing within a borehole thattraverses a subterranean formation has been described that includes afirst wellbore casing for positioning within the borehole and couplingthe first wellbore casing to the borehole, positioning a second wellborecasing within the borehole such that the second wellbore casing overlapswith and is coupled to a portion of the first wellbore casing therebyforming a joint, positioning a tubular sleeve so that it overlaps withand is coupled to at least a portion of the first wellbore casing and toa portion of the second wellbore casing, the tubular sleeve extending alength in either axial direction from the joint between the first andsecond wellbore casings, causing the tubular sleeve to collapse inwardlyonto the respective end portions of the first and second wellborecasings and to sealingly engage the exterior surfaces of the endportions of the first and second wellbore casings respectively on eitherside of the joint there between, thereby facilitating sealing the joint.

In an exemplary embodiment, the method further includes regularlyexpanding and plastically deforming the overlapping portions of thefirst and second wellbore casing and regularly expanding and plasticallydeforming the tubular sleeve that was sealingly collapsed onto theoverlapping portions of the first and second wellbore casings. In anexemplary embodiment, the exterior diameters of the first and secondwellbore casings axially adjacent to the joint there between aresubstantially equal. In an exemplary embodiment, the inside diameters ofthe first wellbore casings and the inside diameter of the secondwellbore casing are substantially equal. In an exemplary embodiment, theinside diameters of the first wellbore casing and the second wellborecasing are substantially constant.

It will further understood by those skilled in the art upon reading theforegoing disclosure and the claims that follow, and upon review of thedrawings that the method may further include forming a wellbore casingwithin a borehole that traverses a subterranean formation includingpositioning first wellbore casing, second wellbore casing and additionalwellbore casings within the borehole that overlaps one with the otherand that are coupled to one another at a joint between each successivewellbore casing. In the method with additional wellbore casings wouldfurther includes additional tubular sleeves positioned to overlap eachsuccessive joint of the successive wellbore casings in causing eachsleeve to collapse inwardly on the respective end portions of the first,second, and additional wellbore casings to sealingly engage the exteriorsurfaces of the respective end portions. The method further includes theuse of magnetic impulse energy to collapse the tubular sleeves onto thesurfaces of the wellbore casings at the joints thereof, therebyfacilitating sealing of the joints.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. A method of forming a wellbore casing within a borehole thattraverses a subterranean formation, comprising: assembling a tubularliner assembly by a process comprising: coupling a threaded portion of afirst tubular member to the threaded portion of a second tubular member;and coupling a tubular sleeve to the threaded portions of the first andsecond tubular members; positioning the tubular liner assembly withinthe borehole; and radially expanding and plastically deforming thetubular liner assembly within the borehole; wherein coupling the tubularsleeve to the threaded portions of the first and second tubular memberscomprises: applying impulsive magnetic energy to the tubular sleeve. 2.A method of forming a coupling between metallic tubular memberscomprising a process comprising: forming a female coupling portion on afirst tubular member; forming a male coupling portion on a secondtubular member; forming at least one raised ridge ring between the maleand female coupling portions; coupling the female coupling portion ofthe first tubular member and the male portion of the second tubularmember including pressing the coupling portions together insurface-to-surface contact; applying a tubular sleeve to exteriorsurfaces of the pressed together coupling portions of the first andsecond tubular members using a magnetic impulse generator; and radiallyexpanding and plastically deforming the coupling between the tubularmembers with the tubular sleeve applied.
 3. The method of claim 2,wherein coupling the male and female coupling portions together furthercomprises forming at least one ridge ring interposed between thecoupling portions to increase the surface-to-surface stress, therebyfacilitating sealing between the first and second tubular members. 4.The method of claim 2 wherein coupling the male and female couplingportions together further comprises forming a layer of material softerthan the metallic tubular members interposed between the couplingportions to increase the surface-to-surface stress, thereby facilitatingsealing between the first and second tubular members.
 5. A method offorming a wellbore casing within a borehole that traverses asubterranean formation, comprising: assembling a tubular liner assemblyby a process comprising: coupling an end of a first tubular member to anend of a second tubular member; and coupling a tubular sleeve to theends of the first and second tubular members; positioning the tubularliner assembly within the borehole: and radially expanding andplastically deforming the tubular liner assembly within the borehole;wherein coupling the tubular sleeve to the ends of the first and secondtubular members comprises: applying impulsive magnetic energy to thetubular sleeve.
 6. A method of forming a coupling between metallictubular members comprising a process comprising the steps of: couplingthe ends of first and second tubular members; applying a tubular sleeveto the ends of the first and second tubular members using magneticenergy; and radially expanding and plastically deforming the couplingbetween the first and second tubular members with the tubular sleeveapplied.
 7. The method of claim 6, wherein coupling the ends of thefirst and second tubular members comprises increasing thesurface-to-surface stress between the first and second tubular members.8. The method of claim 6, wherein coupling the ends of the first andsecond tubular members comprises forming a layer of material softer thanthe ends of the first and second tubular members interposed between theends of the first and second tubular members.
 9. A system for forming awellbore casing within a borehole that traverses a subterraneanformation, comprising: means for assembling a tubular liner assemblycomprising: means for coupling a threaded portion of a first tubularmember to the threaded portion of a second tubular member; and means forcoupling a tubular sleeve to the threaded portions of the first andsecond tubular members; means for positioning the tubular liner assemblywithin the borehold: and means for radially expanding and plasticallydeforming the tubular liner assembly within the borehole; wherein meansfor coupling the tubular sleeve to the threaded portions of the firstand second tubular members comprises: means for applying impulsivemagnetic energy to the tubular sleeve.
 10. A system for forming acoupling between metallic tubular members comprising: means for forminga female coupling portion on a first tubular member; means for forming amale coupling portion on a second tubular member; means for forming atleast one raised ridge ring between the male and female couplingportions; means for coupling the female coupling portion of the firsttubular member and the male portion of the second tubular memberincluding pressing the coupling portions together in surface-to-surfacecontact; means for applying a tubular sleeve to exterior surfaces of thepressed together coupling portions of the first and second tubularmembers using magnetic energy; and means for radially expanding andplastically deforming the coupling between the tubular members with thetubular sleeve applied.
 11. The system claim 10, wherein means forcoupling the male and female coupling portions together furthercomprises means for forming at least one ridge ring interposed betweenthe coupling portions to increase the surface-to-surface stress.
 12. Thesystem of claim 10, wherein means for coupling the male and femalecoupling portions together further comprises means for forming a layerof material softer than the metallic tubular members interposed betweenthe coupling portions to increase the surface-to-surface stress, therebyfacilitating sealing between the first and second tubular members.
 13. Asystem for forming a wellbore casing within a borehole that traverses asubterranean formation, comprising: means for assembling a tubular linerassembly by a process comprising: means for coupling an end of a firsttubular member to an end of a second tubular member; and means forcoupling a tubular sleeve to the ends of the first and second tubularmembers; means for positioning the tubular liner assembly within theborehole; and means for radially expanding and plastically deforming thetubular liner assembly within the borehold; wherein means for couplingthe tubular sleeve to the ends of the first and second tubular memberscomprises: applying impulsive magnetic energy to the tubular sleeve. 14.A system for forming a coupling between the metallic tubular memberscomprising: means for coupling the ends of first and second tubularmembers; means for applying a tubular sleeve to the ends of the firstand second tubular members using magnetic energy; and means for radiallyexpanding and plastically deforming the coupling between the first andsecond tubular members with the tubular sleeve applied.
 15. The systemof claim 14, wherein means for coupling the ends of the first and secondtubular members comprises means for increasing the surface-to-surfacestress between the first and second tubular members.
 16. The system ofclaim 14, wherein means for coupling the ends of the first and secondtubular members comprises means for forming a layer of material softerthan the ends of the first and second tubular members interposed betweenthe ends of the first and second tubular members.